Battery disconnect device

ABSTRACT

Various implementations include a battery disconnect device that includes a breaker, a housing, and a bus bar. The breaker has a pivot portion and an actuation portion, and the actuation portion has an actuation face. The pivot portion has an axis of rotation about which the breaker is pivotable. The housing defines a chamber, and the chamber is in fluid communication with a gas generator via an inlet defined by an inlet wall of the housing. The breaker is disposed within the chamber in a first position in which the actuation face is adjacent the inlet and inlet wall and combustion gas from the gas generator pushes on the actuation face to cause the breaker to pivot about the axis of rotation of the pivot portion to a second position, which causes the breaker to break the bus bar.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of application Ser. No. 15/639,710,entitled “Battery Disconnect Device,” filed Jun. 30, 2017, which claimspriority to U.S. Patent Application No. 62/356,945, entitled “BatteryDisconnect Device,” filed Jun. 30, 2016, the content of which are hereinincorporated by reference in their entirety.

BACKGROUND

Disconnect devices may be included in vehicles to disconnect the batteryduring an accident to ensure that no electrical cables are shortedduring and after the accident and to protect on board electrical systemsdownstream of the disconnect device. Most known disconnect devicesinclude a piston style cutting device to break and separate a bus bar.The piston style cutting devices are actuated by a gas generator (e.g.,pyrotechnic initiator). The piston style cutting devices typically havea blade that shears the bus bar in a predetermined spot.

In addition, current disconnect devices do not provide an ability foremergency personnel and others to visually determine whether the bus barhas been broken, which can present a hazard to the emergency personnelor others attending to the accident.

BRIEF SUMMARY

Various implementations include a battery disconnect device thatincludes a breaker, a housing, and a bus bar. The breaker has a pivotportion and an actuation portion. The actuation portion has an actuationface, and the pivot portion has an axis of rotation about which thebreaker is pivotable. The housing defines a chamber, and the chamber isin fluid communication with a gas generator via an inlet defined by aninlet wall of the housing. The bus bar extends through the housing andthe chamber. The breaker is disposed within the chamber in a firstposition in which the actuation face is adjacent the inlet and inletwall and combustion gas from the gas generator pushes on the actuationface to cause the breaker to pivot about the axis of rotation of thepivot portion to a second position. In the second position, theactuation face is spaced apart from the inlet and inlet wall, and thepivoting movement of the pivot portion causes the breaker to break thebus bar.

In some implementations, the bus bar extends through a groove defined inthe pivot portion of the breaker, and the pivoting movement of the pivotportion causes the pivot portion to break the bus bar at a firstrecessed portion and a second recessed portion. In a furtherimplementation, the groove has first and second walls that are spacedapart from each other. An edge of the first wall and a cylindrical wallof the pivot portion define a first axial groove, and an edge of thesecond wall and the cylindrical wall define a second axial groove,wherein the first axial groove and the second axial groove arecircumferentially spaced apart from each other. In a further oralternative implementation, the groove has a floor, and one edge of thebus bar is disposed adjacent the groove floor.

In some implementations, the pivot portion has a first axial face and asecond axial face, and the housing defines a first recess on a firstwall and a second recess on a second wall. The first wall and the secondwall are spaced apart from each other, and at least a portion of thefirst axial face is engaged in the first recess and at least a portionof the second axial face is engaged in the second recess. In a furtherimplementation, at least one of the first recess or the second recess isan opening in the respective first or second wall of the housing, andthe respective first or second axial face is visible through the openingfrom outside the housing. In a further implementation, the visible firstor second axial face includes an indicator thereon, and the indicatorindicates whether the breaker is in the first position or the secondposition.

In some implementations, the housing includes a wall that defines anopening, and at least a portion of the bus bar and/or breaker is visiblethrough the opening.

In some implementations, the pivot portion is cylindrically shaped, andthe actuation portion extends from a portion of a cylindrical wall ofthe cylindrically shaped pivot portion. In certain implementations, theactuation portion is wedge shaped and tapers in a radially outwarddirection from the cylindrical wall. However, in other implementations,the actuation portion is wedge shaped and tapers in a radially inwarddirection toward the cylindrical wall.

In some implementations having a wedge shaped actuation portion taperingin a radially inward direction, the bus bar includes a disconnectportion that defines a first recessed portion that is adjacent the pivotportion. The actuation portion includes a second face that is spacedapart from the actuation face, and the first recessed portion faces awayfrom the second face of the actuation portion of the breaker. A portionof the disconnect portion of the bus bar bends about the first recessedportion in response to the pivoting of the breaker from the firstposition to the second position. In addition, in a furtherimplementation, the disconnect portion defines a second recessed portionfacing the second face of the breaker, wherein the first and secondrecessed portions face opposite directions and are spaced apart fromeach other along a length of the disconnect portion of the bus bar. Thebus bar breaks at the second recessed portion in response to thepivoting of the breaker from the first position to the second position.In some implementations, the second recessed portion defines a V-shapedstress riser, and the first recessed portion defines a U-shaped recessedportion.

In another implementation having a wedge shaped actuation portiontapering in a radially inward direction, the bus bar includes adisconnect portion that defines a recessed portion, such as the secondrecessed portion described above that faces the second face of theactuation portion of the breaker, and the bus bar breaks at the recessedportion in response to the pivoting of the breaker from the firstposition to the second position. In some implementations, the recessedportion defines a V-shaped stress riser.

In some implementations, the battery disconnect device further includesa gasket disposed between the actuation face and the inlet wall.

In some implementations, the bus bar includes a first lead and a secondlead, and the first and second leads extend outwardly relative to anexternal surface of the housing.

In some implementations, the actuation face lies in a first plane and asecond face lies in a second plane. The inlet wall of the chamber liesin a third plane, and the housing further includes a stop wall that liesin a fourth plane and an arcuate shaped wall disposed between the stopwall and the inlet wall. The third and fourth planes intersect oppositethe arcuate shaped wall of the housing. The breaker includes an arcuateshaped face extending between the actuation face and the second face,and the arcuate shaped face is opposite and spaced apart from the pivotportion. The arcuate shaped wall of the chamber faces the arcuate shapedface of the breaker. The pivot portion of the breaker is disposedadjacent the intersection of the third and fourth planes. In a furtherimplementation, the arcuate shaped face of the breaker includes at leastone tooth that extends away from the arcuate shaped face. The toothengages the arcuate shaped wall after the breaker rotates from the firstposition to the second position to prevent rotation from the secondposition to the first position. In a further implementation, the atleast one tooth comprises a first plurality of teeth and the arcuateshaped wall defines a second plurality of teeth that extend away fromthe arcuate shaped wall and engage the first plurality of teeth afterthe breaker rotates from the first position to the second position toprevent rotation from the second position to the first position.

In some implementations, the arcuate shaped wall includes a firstportion and a second portion. The first portion of the arcuate shapedwall extends from the inlet wall, and the second portion of the arcuateshaped wall extends from the stop wall. The distal ends of the first andsecond portions define a first gap therebetween through which a firstend portion of the bus bar extends.

In some implementations, the bus bar includes a first end portionextending between a first lead and the disconnect portion. The firstlead extends outwardly relative to an external surface of the housing,and the first end portion extends through the first gap.

In some implementations, the housing defines an arcuate shaped lipextending from the inlet wall toward the stop wall. The lip is spacedapart from and facing opposite the arcuate shaped wall, and the pivotportion of the wedge shaped breaker engages the arcuate shaped lip inthe first and second positions. In a further implementation, the arcuateshaped lip and the stop wall define a second gap therebetween, and thebus bar includes a second end portion extending between a second leadand the disconnect portion. The second lead extends outwardly relativeto the external surface of the housing, and the second end portionextends through the second gap.

In some implementations, an angle of intersection of the first andsecond planes is less than 90°. For example, in one implementation, theangle of intersection of the first and second planes is between 30° and45°.

In other various implementations, a battery disconnect device includes abreaker, a housing, and a bus bar. The breaker has an indicator on aportion thereof. The housing defines a chamber, and the breaker isdisposed in the chamber. The bus bar is disposed through the housing.Combustion gas from a gas generator causes the breaker to move from afirst position to a second position, wherein movement from the firstposition to the second position causes the breaker to break the bus barinto at least two separate pieces, and the indicator is visible from anexternal surface of the housing when the breaker is in the secondposition.

In some implementations, the indicator is visible from the externalsurface of the housing when the breaker is in the first position. Incertain implementations, the indicator is a tab that extends from anexternal surface of the breaker, and the tab moves with the breaker fromthe first position to the second position. The tab is visible from theexternal surface of the housing through a window defined by the externalsurface of the housing. In a further implementation, the window is aslot, and the tab moves through the slot from the first position to thesecond position. In another implementation, the tab is an axial face ofa pivot portion of the breaker, and the tab includes an indicator thatrotates with the pivot portion about an axis of rotation R-R of thepivot portion to indicate whether the breaker is in the first positionor the second position.

In other various implementations, a battery disconnect device includes abreaker, a housing, and bus bar. The housing defines a chamber, and thebreaker is disposed in the chamber. The bus bar is disposed through thehousing. Combustion gas from a gas generator causes the breaker to movefrom a first position to a second position, and movement from the firstposition to the second position causes the breaker to break the bus barinto at least two separate pieces. The housing defines a window throughwhich at least a portion of the breaker and/or the bus bar is visiblefrom an external surface of the housing when the breaker is in the firstand/or second position.

BRIEF DESCRIPTION OF THE DRAWINGS

Various implementations are explained in even greater detail in thefollowing exemplary drawings. The drawings are merely exemplary toillustrate the structure of the implementations and certain featuresthat may be used singularly or in combination with other features. Theinvention should not be limited to the implementations shown.

FIGS. 1A and 1B illustrate upper and lower perspective views of abattery disconnect device according to one implementation.

FIG. 2A illustrates a plan view of components disposed within thebattery disconnect device shown in FIGS. 1A and 1B in the non-deployedposition.

FIG. 2B illustrates a plan view of components disposed within thebattery disconnect device shown in FIG. 2A in the deployed position.

FIG. 3 illustrates an exploded view of the components of the batterydisconnect device shown in FIGS. 1A through 2B.

FIG. 4 illustrates a partial perspective view of a breaker according toanother implementation.

FIG. 5 illustrates a plan view of the breaker shown in FIG. 4 disposedwithin a battery disconnect device according to another implementation.

FIG. 6 illustrates a partial perspective view of a battery disconnectdevice according to another implementation.

FIG. 7 illustrates a partial perspective view of a first housing portionof the battery disconnect device shown in FIG. 6.

FIG. 8 illustrates a partial perspective view of a second housingportion of the battery disconnect device.

FIG. 9 illustrates a perspective view of the breaker shown in FIG. 6.

FIG. 10 illustrates a perspective view of the battery disconnect deviceshown in FIG. 6.

FIG. 11 illustrates a partial perspective view of a battery disconnectdevice according to another implementation.

FIGS. 12 and 13 illustrate perspective views of the breaker shown inFIG. 11.

FIG. 14 illustrates a partial perspective view of the breaker shown inFIGS. 12 and 13 and a second housing portion.

FIG. 15 illustrates the second housing portion shown in FIG. 14.

FIG. 16 illustrates a plan view of a first housing portion, which isalso shown in FIG. 11.

FIG. 17 illustrates the assembled battery disconnect device 300 shown inFIGS. 11-16.

FIG. 18 illustrates a partial perspective view of the battery disconnectdevice shown in FIG. 11 with the bus bar broken.

FIG. 19 illustrates a linear actuator type disconnect device accordingto another implementation.

FIG. 20 illustrates a partial perspective view of the disconnect deviceshown in FIG. 19.

FIG. 21 illustrates a linear actuator type disconnect device accordingto another implementation.

FIG. 22 illustrates a partial perspective view of the disconnect deviceshown in FIG. 21.

DETAILED DESCRIPTION

Various implementations include a battery disconnect device thatincludes a breaker, a housing, and a bus bar. The breaker has a pivotportion and an actuation portion, and the actuation portion has anactuation face. The pivot portion has an axis of rotation about whichthe breaker is pivotable. The housing defines a chamber, and the chamberis in fluid communication with a gas generator via an inlet defined byan inlet wall of the housing. And, the bus bar extends through thehousing and the chamber. The breaker is disposed within the chamber in afirst position in which the actuation face is adjacent the inlet andinlet wall and combustion gas from the gas generator pushes on theactuation face to cause the breaker to pivot about the axis of rotationof the pivot portion to a second position. In the second position, theactuation face is spaced apart from the inlet and inlet wall, and thepivoting movement of the pivot portion causes the breaker to break thebus bar.

In addition, other various implementations include a battery disconnectdevice that includes a breaker, a housing, and a bus bar. The breakerhas an indicator on a portion thereof. The housing defines a chamber,and the breaker is disposed in the chamber. And, the bus bar is disposedthrough the housing. The combustion gas from a gas generator causes thebreaker to move from a first position to a second position, and movementfrom the first position to the second position causes the breaker tobreak the bus bar into at least two separate pieces. The indicator isvisible from an external surface of the housing when the breaker is inthe second position.

Furthermore, other various implementations include a battery disconnectdevice that includes a breaker, a housing, and a bus bar. The housingdefines a chamber, and the breaker is disposed in the chamber. The busbar is disposed through the housing. Combustion gas from a gas generatorcauses the breaker to move from a first position to a second position,and movement from the first position to the second position causes thebreaker to break the bus bar into at least two separate pieces. Thehousing defines a window through which at least a portion of the breakerand/or the bus bar is visible from an external surface of the housingwhen the breaker is in the first and/or second position.

FIGS. 1A-3 illustrate an exemplary battery disconnect device accordingto one implementation. The battery disconnect device 100 includes ahousing 102, a breaker 104, and a bus bar 105. The housing 102 andbreaker 104 are formed from materials that are not electricallyconductive (e.g., a polymer or glass filled polymer (e.g., glass fillednylon), and the bus bar 105 is a conductive material (e.g., metal,composite with metal).

The housing 102 includes an inlet wall 112, a stop wall 132, and anarcuate shaped wall 134. A chamber 106 within the housing 102 is definedat least in part by the inlet wall 112, the stop wall 132, the arcuateshaped wall 134, and side walls 150, 151 of the housing 102. At least aportion of the inlet wall 112 lies within a first plane, and at least aportion of the stop wall 132 lies within a second plane that intersectsthe first plane. And, the arcuate shaped wall 134 is disposed betweenthe stop wall 132 and the inlet wall 112 opposite the intersection ofthe first and second planes. The inlet wall 112 defines an inlet 110,and a gas generator 108 (e.g., an initiator or micro gas generator(MGG)) is in fluid communication with the chamber 106 via the inlet 110.An arcuate shaped lip 142 extends from the inlet wall 112 toward thestop wall 132, and a gap is defined between the lip 142 and the stopwall 132. The lip 142 is spaced apart from and faces opposite thearcuate shaped wall 134. In addition, the lip 142 is adjacent theintersection of the first and second planes.

The arcuate shaped wall 134 includes a first arcuate shaped wall portion134 a that extends from the inlet wall 112 and a second arcuate shapedwall portion 134 b that extends from the stop wall 132. The firstarcuate shaped wall portion 134 a and second arcuate shaped wall portion134 b define a gap between the distal ends thereof. In otherimplementations (not shown), the arcuate shaped wall 134 may include oneof the first arcuate shaped wall portion 134 a or the second arcuateshaped wall portion 134 b.

The breaker 104 has an actuation portion 111 and a pivot portion 118.The actuation portion 111 includes a first face 114 that lies in a thirdplane, a second face 116 that lies in a fourth plane, and an arcuateshaped face 136 opposite the pivot portion 118. The actuation portion111 is wedge shaped and tapers radially inwardly toward the pivotportion 118. An angle of intersection of the third and fourth planes isbetween 30° and 45°. The first face 114 and the second face 116 eachhave first edges 144 a, 144 b, respectively, that are spaced apart fromeach other a first distance and second edges 145 a, 145 b, respectively,that are spaced apart from each other a second distance that is lessthan the first distance. The arcuate shaped face 136 extends between thefirst edges 144 a, 144 b of the first face 114 and the second face 116.The pivot portion 118 extends between the second edges 145 a, 145 b ofthe first face 114 and the second face 116, and the pivot portion 118 isopposite and spaced apart from the arcuate shaped face 136 and isadjacent an intersection of the third and fourth planes. In theimplementations shown in FIGS. 2A through 3, the pivot portion 118 hasan arcuate shape. In other implementations, the angle of intersectionmay be less than 90°. In addition, in other implementations, the pivotportion 118 and/or the face extending between the first face 114 and thesecond face 116 may have a non-arcuate shape.

The bus bar 105 includes an interior portion 122 disposed within thechamber 106 and electrical connection leads 124 a, 124 b that aredisposed externally of the chamber 106. The interior portion 122includes a first end portion 146, a second end portion 147, and adisconnect portion 120 that extends between the first end portion 146and the second end portion 147. The disconnect portion 120 defines afirst recessed portion 128 and a second recessed portion 121. The firstrecessed portion 128 and the second recessed portion 121 are defined onsurfaces of the bus bar 105 that face opposite directions and are spacedapart from each other, and the recessed portions 128, 121 are spacedapart along a length of the disconnect portion 120 of the bus bar 105(i.e., the direction extending between the first end portion 146 and thesecond end portion 147). In the implementation shown in FIGS. 2A through3, the second recessed portion 121 defines a v-shaped stress riser, orgroove, and the first recessed portion 128 defines a U-shaped recessedportion. However, in other implementations, the recessed portions 121,128 may define recessed portions having other shapes. In addition, insome implementations (not shown), the bus bar 105 may include the firstrecessed portion 128 or the second recessed portion 121 and not theother.

The leads 124 a, 124 b extend through and away from side wall 151 of thehousing 102. Each of the leads 124 a, 124 b extends through the sidewall 151 of the housing 102 and turns outwardly to extend past afootprint of the housing 102 such that distal ends of the leads 124 a,124 b lie in a plane that is parallel with the side wall 151 of thehousing 102. Axis A-A within this plane extends centrally through lead124 a, and axis B-B within this plane extends centrally through lead 124b. Axis A-A and axis B-B are parallel and spaced apart from each other.

The first end portion 146 extends from a proximal end of lead 124 a andthe second end portion 147 extends from a proximal end of lead 124 b.The first 146 and second end portions 147 lie in separate planes thatare spaced apart from and are parallel to each other and areperpendicular to the plane that include the distal ends of the leads 124a, 124 b. The disconnect portion 120, which extends between the first146 and second end portions 147, lies in a plane that intersects theplanes in which the end portions 146, 147 lie. For example, in someimplementations, the plane in which the disconnect portion 120 liesintersects the planes in which first 146 and second end portions 147 lieat an angle of between 30° and 45°. In other implementations, the anglemay be less than 90° and may correspond to the angle at which the thirdand fourth planes of the breaker 104 intersect.

FIGS. 2A and 2B illustrate the breaker 104 and bus bar 105 assembledwithin the chamber 106 of the housing 102. The disconnect portion 120 ofthe bus bar 105 extends through the chamber 106, and the leads 124 a,124 b extend from the side wall 151 of the housing 102. The first endportion 146 of the bus bar 105 extends through the gap defined betweenthe inlet wall 112 and the stop wall 132, and the second end portion 147of the bus bar 105 extends through the gap defined between distal endsof the first arcuate shaped wall portion 134 a and second arcuate shapedwall portion 134 b. And, in some implementations (not shown), the leadsmay extend through and from another external surface of the housing 102than side wall 151.

The breaker 104 is disposed within the chamber 106 between the inletwall 112 and the bus bar 105 in the first, or non-deployed, position,which is shown in FIG. 2A. In this first position, the first face 114 ofthe actuation portion 111 faces the inlet 110 and the inlet wall 112 ofthe housing 102, the second face 116 faces the disconnect portion 120 ofthe bus bar 105, and the arcuate shaped face 136 of the breaker 104faces the first arcuate shaped wall portion 134 a. In addition, thepivot portion 118 of the breaker 104 engages the arcuate shaped lip 142.

Combustion gas from the gas generator 108 forces the breaker 104 topivot about an axis of rotation R-R of the pivot portion 118 from thefirst, or non-deployed, position shown in FIG. 2A to the second, ordeployed, position shown in FIG. 2B, and the pivoting causes the secondface 116 of the breaker 104 to break the disconnect portion 120 of thebus bar 105 at the second recessed portion 121.

In the second position, the first face 114 is spaced apart from theinlet 110 and inlet wall 112, and the second face 116 is disposedadjacent the stop wall 132. In addition, the arcuate shaped face 136faces the second arcuate shaped wall portion 134 b. The portion of thebus bar 105 between the recessed portions 128, 121 is bent about thesecond recessed portion 121 and is disposed between the second face 116and the stop wall 132 in the deployed position.

The battery disconnect device 100 also includes a gasket 130 that isdisposed between the first face 114 of the breaker 104 and the inletwall 112. The gasket 130 prevents leakage of gas from the gas generator108 past the first face 114 of the breaker 104.

In the implementation shown in FIG. 4, the arcuate shaped face 136′ ofthe breaker 104′ includes teeth 138′ to prevent rotation from the secondposition to the first position. The teeth 138′ extend radially outwardlyfrom the arcuate shaped face 136′ and are angled such that they slidepast the arcuate shaped wall 134 when the breaker 104 rotates from thefirst position to the second position and engage the arcuate shaped wall134 in response to rotation or attempted rotation from the secondposition toward the first position.

In the implementation shown in FIG. 5, the arcuate shaped wall portion134 b′ also includes teeth 140′ that extend radially inwardly from thearcuate shaped wall portion 134 b′ and are angled such that the teeth138′ can slide past the teeth 140′ when the breaker 104′ moves from thefirst position to the second position. The teeth 140′ from the arcuateshaped wall portion 134 b′ engage the teeth 138′ from the arcuate shapedface 136′ in response to movement or attempted movement from the secondposition toward the first position to prevent rotation in thisdirection. The teeth 140′ also decelerate the breaker 104′, whichfurther prevents bounce back of the breaker 104′ in the direction fromthe second position to the first position. Although not shown, the firstarcuate shaped wall portion may also include teeth, such as teeth 140′.

In the implementation shown in FIGS. 6-10, the battery disconnect device200 includes a breaker 204, housing having a first housing portion 202 aand a second housing portion 202 b, and a bus bar, such as bus bar 105.The breaker 204 includes a pivot portion 218 and an actuation portion211. Axial faces of pivot portion 218 include first and second pinportions 219 a, 219 b that extend from each side of the pivot portion218 along rotational axis R-R of the pivot portion 218. The actuationportion 211 includes first face 214, a second face 216, and an arcuateshaped face 236 that extends between the first face 214 and the secondface 216 and is spaced apart and opposite the pivot portion 218.

In the implementation described in relation to FIGS. 1-5, the secondface 116 of the breaker 104 is relatively flat. Thus, the entire area ofthe second face 116 of the breaker 104 applies the actuation force tothe bus bar 105. However, in the implementation shown in FIGS. 6-10, thesecond face 216 provides at least two concentrated load areas forapplying the actuation force to the bus bar 105. In the implementationshown in FIGS. 6-10, the concentrated load areas are provided by thearea 216 a between peripheral edges 285 c, 285 d of a triangular shapedgroove 285 defined by the second face 216 and peripheral edges 216 b,216 c of the second face 216. The triangular shaped groove 285 istriangular shaped as viewed from a plan view of the second face 216, andthe groove 285 is further defined by two triangular shaped faces 285 a,285 b. The apices of the faces 285 a, 285 b are spaced apart from adistal end of the second face 216 and meet at a single point. In otherwords, the groove 285 tapers from the arcuate shaped face 236 toward thepivot portion 218 and tapers from the second face 216 toward the firstface 214. The peripheral edges 285 c, 285 d of the groove 285 are thespaced apart sides of each triangular shaped face 285 a, 285 b.Providing multiple concentrated load areas for applying the actuationforce against the bus bar 105 improves the ability to break the bus bar105.

The first housing portion 202 a, which is shown in FIGS. 6 and 7,includes inlet wall 212 defining inlet 210, a stop wall 232, a side wall250, and an arcuate shaped wall 234 that extends from the inlet wall 212into the chamber 206. Side wall 250 defines a recess 260 a.

The second housing portion 202 b, which is shown in FIG. 8, includes aside wall 251 and an arcuate shaped wall 235. The side wall 251 definesa recess 260 b.

To assemble the battery disconnect device 200, pin portion 219 a of thebreaker 204 is engaged into recess 260 a, and the disconnect portion 122of the bus bar 105 is disposed within the chamber 206. The arcuate wall235 of the second portion 202 b of the housing is disposed withinchamber 206 such that the arcuate wall 235 is spaced apart from andbetween a distal edge of arcuate wall 234 of housing portion 202 a andthe stop wall 232 to define gaps through which the bus bar 105 extends.The pin portion 219 b extends through recess 260 b. The engagement ofthe pin portions 219 a, 219 b in the recesses 260 a, 260 b allows thebreaker 204 to pivot about the axis R-R and restricts lateral movementof the pins 219 a, 219 b relative to the side walls 250, 251.

Recess 260 a is a window that extends to an outer surface 264 of thesidewall 250, as shown in FIG. 10. As shown in FIG. 10, the pin portion219 a engages recess 260 a, and the distal end face 267 of the pinportion 219 a includes an arrow shaped indicator 266. The arrow shapedindicator 266 is visible from outside of the housing via the recess 260a. When the breaker 204 pivots from the first position to the secondposition, the indicator 266 rotates from a first indicator position to asecond indicator position with the breaker 204. The first indicatorposition is shown in FIG. 6, indicating that the breaker 204 is in thefirst position and the bus bar 105 is not broken. In the secondindicator position, the arrow 266 rotates to indicate that the breaker204 is in the second position and the bus bar is broken. The outersurface 264 of the sidewall 250 of the housing portion 202 a adjacentthe recess 260 a includes indicators 278 that aligns with the arrowshaped indicator 266 on the distal end face of the pin portion 219 a ineach of the first and second positions and indicates whether the breaker204 is in the first position or second position. The visual indicators266, 278 allow emergency responders or others to visually confirmwhether power from the battery has been disconnected by the breaker 204.

The various implementations of a battery disconnect device having apivot portion break the bus bar faster and require less gas volume thanprior art solutions that have piston style actuators. In particular, inthe implementations shown in FIGS. 1-10, the gas generator is spacedapart from the pivot portion of the breaker, which results in theinitial actuation force being applied closer to the predeterminedweakest point of the bus bar. Also, according to some implementations, abreaker having the same actuation surface area as a piston styleactuator requires half of the gas volume for actuation than is requiredfor the piston style actuator. The battery disconnect device alsoprovides more distance between the broken ends of the bus bar to resistarcing between the broken ends of the bus bar after the breaker isdeployed.

FIGS. 11-18 illustrate another implementation of a battery disconnectdevice 300. In this implementation, the battery disconnect device 300includes breaker 304, housing 302, and bus bar 305. As shown in FIGS.12-13, the breaker 304 includes a cylindrically shaped pivot portion 318and an actuation portion 311 that extends from an outer radial edge ofthe pivot portion 318. The pivot portion 318 has a first axial face 319and a second axial face 383 that is axially spaced apart and oppositethe first axial face 319 along axis R-R. A cylindrical side wall 323extends between the first 319 and second axial faces 383. The firstaxial face 319 and a portion of the cylindrical side wall 323 define agroove 370 that extends axially into the pivot portion 318. The groove370 has a first side wall 374 and a second side wall 376 that are spacedapart from each other, and a floor 372 extends between the first 374 andsecond side walls 376. The groove 370 is centered in the pivot portion318 such that the axis R-R intersects a center of the groove floor 372.The groove floor 372 is axially spaced apart from the first axial face319.

As shown in FIGS. 12 and 13, the cylindrical wall 323 and an edge 377 ofthe second wall 376 adjacent end 372 b of the groove floor 372 define anaxial groove 375 that extends from the first axial face 319 toward thegroove floor 372. The axial groove 375 includes a rectangular shapedface 375 a and a triangular shaped face 375 b. The triangular shapedface 375 b tapers from the first axial face 319 toward the groove floor372. Adjacent edges of the faces 375 a, 375 b are coaxial. Similarly,the cylindrical wall 323 and an edge 379 of the first wall 374 adjacentend 372 a of the groove floor 372 define an axial groove 373 thatextends from the first axial face 319 toward the groove floor 372. Theaxial groove 373 includes a rectangular shaped face 373 a and atriangular shaped face 373 b that tapers from the first axial face 319toward the groove floor 372. Adjacent edges of the faces 373 a, 373 bare coaxial. The edge 379 of the first wall 374 and the edge 377 of thesecond wall 376 provide a concentrated load on the portion of the busbar 305 adjacent each of the edges 379, 377 as the edges 379, 377 comeinto contact with the bus bar 305. In addition, edges of the cylindricalwall 323 adjacent each groove 373, 375 also provide a concentrated loadon the bus bar 305 adjacent these edges as the bus bar 305 elongates andcomes into contact with these edges, which further assists with cuttingthe bus bar 305. During rotation of the pivot portion 318, the pivotportion 318 begins to cut the bus bar 305 at the edge of the bus bar 305adjacent the groove floor 372, and continued rotation of the pivotportion 318 allows the edges 379, 377 to continue to cut the bus bar 305through to the edge of the bus bar 305 adjacent the axial face 319. Asthe pivot portion 318 rotates and begins to cut the bus bar 305, the busbar 305 elongates slightly at each cut location. The grooves 373, 375 inthe pivot portion 318 and the expansion portions 365 a, 365 b of thesemi-cylindrical opening 365 described below allow space for theelongation of the bus bar 305. The ends 372 a, 372 b of the groove 372are radially spaced apart from each other. In other implementations, aconcentrated load may be applied to the bus bar 305 by an edge of agroove having one or more faces having other shapes (e.g., bothrectangular, both triangular, one or more arcuate, one or moretrapezoidal).

The actuation portion 311 is wedge shaped and tapers in a radiallyoutward direction. In particular, the actuation portion 311 includes afirst face 314, which is an actuation face, and a second face 316. Atleast a portion of the first face 314 lies in a first plane, and atleast a portion of the second face 316 lies in a second plane. The firstand second planes intersect at an angle of less than 90° (e.g., between30 and 45°. The actuation portion 311 also includes a third face 317 anda fourth face 313. At least a portion of the third face 317 extends in athird plane, and the third plane and second plane intersect at an angleat least 90° and less than 180°. At least a portion of the fourth face313 extends in a fourth plane, and the fourth plane and the first planeintersect at an angle of at least 90° and less than 180°. The third face317 extends from a distal edge of the second face 316, and the fourthface 313 extends from a distal edge of the first face 314. The thirdface 317 and fourth face 313 have a common distal edge. However, inother implementations, the actuation portion 311 may be shapeddifferently. For example, in other implementations, the third 317 and/orfourth faces 313 or may not be wedge shaped, the distal end of theactuation portion 311 may be arcuate shaped, the actuation portion 311may be rectangular shaped, the actuation portion 311 may defined one ormore teeth extending from a distal end thereof, or the actuation portion311 may have one or more arcuate shaped faces.

In addition, in the implementation shown in FIGS. 11-18, the housing 302includes a first portion 302 a and a second portion 302 b. When coupledtogether, the first portion 302 a and second portion 302 b definechamber 306. The first portion 302 a includes an inlet wall 312, stopwall 332, an arcuate shaped wall 331 extending from the inlet wall 312,and side wall 350, similar to the implementations described above. Thesecond portion 302 b includes side wall 351. The first portion 302 a andthe second portion 302 b are separately formed from each other.

To couple the housing portions 302 a, 302 b together, housing portion302 b includes legs 391 a, 391 b and legs 392 a, 392 b that extendaxially from side wall 351. The legs 391 a, 391 b, 392 a, 392 b engagegrooves 393 a, 393 b, 397 a, 397 b, respectively, defined on externalsurfaces of housing portion 302 a. Each groove 393 a, 393 b, 397 a, 397b includes a tab 398 that extends outwardly from the respective groove,and a slot 399 defined in each leg receives the tab 398 to prevent thehousing portions 302 a, 302 b from being pulled apart.

The housing portion 302 b also includes a wall 334 that extends fromside wall 351. The wall 334 includes an outer portion 334 d, an innerarcuate shaped portion 334 a that defines one or more teeth 334 b, andan inner triangular portion 334 c spaced apart from the inner arcuateshaped surface 334 a.

The teeth 334 b engage the distal end of the actuation portion 311 ofthe breaker 304 to prevent the breaker 304 from rotation opposite theactuation direction. Side wall 350 of housing portion 302 a defines afirst triangular shaped opening 355, a second triangular shaped opening352, and a rectangular shaped groove 353 within side wall 354, whichextends from side wall 350. When coupling the housing portions 302 a,302 b together, the outer portion 334 d of wall 334 engages the groove353, a distal end of the inner arcuate shaped portion 334 a engages thesecond triangular shaped opening 352, and a distal end of the innertriangular shaped portion 334 c engages the first triangular shapedopening 355. Engagement of the portions 334 a, 334 c, 334 d of thehousing portion 302 b into the respective openings 352, 355 and groove353 of the housing portion 302 a provides stability to the housing 302during operation.

The first portion 302 a of the housing 302 defines a semi-cylindricalopening 365 into which the pivot portion 318 is disposed. Thesemi-cylindrical opening 365 is defined by and between the inlet wall312 and the stop wall 332. The opening 365 has first 365 a and secondenlarged opening portions 365 b and a non-enlarged opening portion 365c. The first 365 a and second enlarged opening portions 365 b have adiameter that is larger than the non-enlarged opening portion 365 c. Theinlet wall 312 defines the first enlarged opening portion 365 a, and thestop wall 332 defines the second enlarged opening portion 365 b. Thearcuate length and diameter of each enlarged opening portion 365 a, 365b is selected to provide sufficient space for the elongation of the busbar 305 when it is broken.

The side wall 351 defines a first recess 360 a, and the side wall 350defines a second recess 360 b. The first axial face 319 of the pivotportion 318 includes a pin portion 319 a that extends axially from thefirst axial face 319, and the pin portion 319 a is engaged in the firstrecess 360 a when the first portion 302 a and the second portion 302 bof the housing 302 are coupled together. The second axial face 383includes a pin portion 383 a that extends axially from the second axialface 383, and the pin portion 383 a is engaged in the second recess 360b. Having the pin portions 319 a, 383 a engage the recesses 260 a, 260 ballows pivoting movement of the breaker 304 and prevents lateralmovement of the breaker 304 relative to axis R-R. In the implementationshown in FIG. 16, at least recess 360 b is an opening defined in theside wall 350, and the distal face of the second pin portion 383 a isvisible through the opening 360 b from outside the housing 302. Thedistal face of the first pin portion 383 a includes an indicator 378thereon that indicates whether the breaker 304 is in the first positionor the second position. The indicator 378 shown in FIG. 14 is an arrow,but in other implementations, the indicator could be a line or othershape. In another implementation, the recess 360 b is a window, and theorientation of the breaker 304 is visible from outside of the housing302 through this window.

The bus bar 305 includes a U-shaped interior portion 322, a firstelectrical lead 324 a, and a second electrical lead 324 b. The U-shapedinterior portion 322 has a first distal end 346, a second distal end 347and a disconnect portion 322 a. The disconnect portion 322 a includes afirst recessed portion 321 and a second recessed portion 328. The firstelectrical lead 324 a extends from the first distal end 346 of theinterior portion 322, and the second electrical lead 324 b extends fromthe second distal end 347 of the interior portion 322. In theimplementation shown in FIG. 11, the leads 324 a, 324 b extend outwardlyfrom the interior portion 322 at 90°. However, in other implementations,the angle at which the leads 324 a, 324 b extend from the distal ends346, 347 may differ, depending on the arrangement of the batterydisconnect device 300 in its end use. Lead 324 a extends from thehousing 302 through a groove 394 defined in stop wall 332, and lead 324b extends from the housing 302 from a groove 396 defined between stopwall 332 and inlet wall 312.

The disconnect portion 322 a is between the distal ends 346, 347. Inparticular, the disconnect portion 322 a is defined between a firstrecessed portion 321 defined on a first surface 366 of the bus bar 305and a second recessed portion 328 defined on a second surface 368 of thebus bar 305. The first surface 366 and the second surface 368 are spacedapart from and opposite each other. The first recessed portion 321 andthe second recessed portion 328 are also spaced apart along a length ofthe disconnect portion 322 a. The recessed portions 321, 328 shown inFIG. 11 are V-shaped, but in other implementations, the recessedportions 321, 328 may be shaped differently (e.g., U-shaped orrectangular shaped).

As shown in FIG. 11, the disconnect portion 322 a is disposed within thegroove 370 of the breaker 304. A first edge of the bus bar 305 isdisposed adjacent to (e.g., abuts) the floor 372 of the groove 370. Asecond edge of the bus bar 305 that is opposite and spaced apart fromthe first edge is within the same plane or below the same plane thatincludes the axial face 319.

In the first or non-deployed position, which is shown in FIGS. 11 and14, the first face 314 of the actuation portion 311 faces and isadjacent the inlet 310 and the inlet wall 312 of the housing 302. Gasket330 is disposed between the first face 314 and the inlet wall 312. Thesecond face 316 faces away from the inlet wall 312. Pin portions 319 a,383 a are engaged within recesses 360 a, 360 b, respectively.

Combustion gas from the gas generator 108 enters chamber the 306 fromthe inlet 310 and forces the breaker 304 to pivot about axis R-R fromthe first position to a second position. In the second position, whichis shown in FIG. 18, the first face 314 is spaced apart from the inletwall 312. The gasket 330 moves with the first face 314 but is not shownin FIG. 18. The pivoting movement of the pivot portion 318 causes thepivot portion 318 to break the bus bar 305 at the first recessed portion321 and the second recessed portion 328. During the pivoting movement,the edges 379, 377 of walls 374, 376, respectively, of the groove 370push against surfaces of the bus bar 305 opposite the first recessedportion 321 and the second recessed portion 328, respectively, causingthe bus bar 305 to break at or adjacent to the recessed portions 321,328. Because the indicator 378 on the distal end of the pin portion 383a rotates with the pivot portion 318 as the breaker 304 moves from thefirst position to the second position, the indicator 378 indicateswhether the bus bar 305 is in tact or broken.

In the implementations described above in relation to FIGS. 6-18, thebreaker rotates from a first position to a second position to break thebus bar, and an indicator on the pin portion of the pivot portionrotates with the pivot portion to indicate the position of the breakerwithin the housing. The indicator is visible from an external surface ofthe housing, allowing emergency personnel or others to visuallydetermine if the bus bar is live or broken. However, in otherimplementations, the ability to view the status of the bus bar isprovided in alternative ways. For example, the housing may define awindow through which a portion of the breaker and/or a portion of thebus bar is visible when the breaker is in one position and not visiblein the other position.

This ability to view the status of the bus bar may also be provided withlinear actuators for breaking bus bars, according to variousimplementations. For example, as shown in FIGS. 19-20, the linearactuator battery disconnect device 400 includes a piston rod 406,housing 402, and bus bar 405. The piston rod 406 is disposed within thehousing 402, and the bus bar 405 extends through the housing 402. Anindicator tab 472 extends radially outwardly from an external surface ofthe piston rod 406 and into a slot 482 defined by one side of thehousing 402. The slot 482 extends to the external surface of the side ofthe housing 402, allowing the position of the tab 472 in the slot 482 tobe viewed from outside of the housing 402. When the piston rod 406 ismoved from a first position to a second position to break the bus bar405, the tab 472 moves axially through the slot 482 from a first end ofthe slot 482 toward a second end of the slot 482. In the implementationshown in FIGS. 19-20, an intact bus bar 405 and the tab 472 are visiblein the first position, but the bus bar 405 would not be visible in thesecond position.

Alternatively, in the implementation shown in FIGS. 21-22, the linearactuator battery disconnect device 500 includes piston rod 506, housing502, and bus bar 505. The piston rod 506 does not have an indicator tabas with battery disconnect device 400, but at least one side wall of thehousing 502 defines a window 578 through which at least a portion of thepiston rod 506 and/or bus bar 505 are visible from outside of thehousing 502. In the implementation shown, the piston rod 506 is notvisible from the window 578 in the first position and is visible fromthe window 578 in the second position, indicating that the bus bar isbroken. However, in other implementations, the window 578 may be definedsuch that a portion of the bus bar 505 is visible from the window 578 inone position but not the other.

The terminology used herein is for the purpose of describing particularimplementations only and is not intended to be limiting of theinvention. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the present invention has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention. Theimplementation was chosen and described in order to best explain theprinciples of the invention and the practical application, and to enableothers of ordinary skill in the art to understand the invention forvarious implementations with various modifications as are suited to theparticular use contemplated.

The invention claimed is:
 1. A battery disconnect device comprising: abreaker having an indicator on a portion thereof; a housing defining achamber, the breaker being disposed in the chamber; and a bus bardisposed through the housing, wherein combustion gas from a gasgenerator causes the breaker to move from a first position to a secondposition, wherein movement from the first position to the secondposition causes the breaker to break the bus bar into at least twoseparate pieces, and the indicator is visible from an external surfaceof the housing when the breaker is in the second position; wherein thebreaker has a pivot portion and an actuation portion, the actuationportion having an actuation face, the pivot portion having an axis ofrotation about which the breaker is pivotable, wherein the chamber is influid communication with a gas generator via an inlet defined by aninlet wall of the housing, the bus bar extending through the housing andthe chamber, wherein the actuation face is adjacent the inlet and inletwall in the first position, and combustion gas from the gas generatorpushes on the actuation face to cause the breaker to pivot about theaxis of rotation of the pivot portion to a second position, wherein inthe second position, the actuation face is spaced apart from the inletand inlet wall; and wherein the bus bar extends through a groove definedin the pivot portion of the breaker, and the pivoting movement of thepivot portion causes the pivot portion to break the bus bar at a firstrecessed portion and a second recessed portion.
 2. The batterydisconnect device of claim 1, wherein the indicator is visible from theexternal surface of the housing when the breaker is in the firstposition.
 3. The battery disconnect device of claim 1, wherein theindicator is a tab that extends from an external surface of the breaker,the tab moving with the breaker from the first position to the secondposition, and the tab being visible from the external surface of thehousing through a window defined by the external surface of the housing.4. The battery disconnect device of claim 3, wherein the tab is an axialface of the pivot portion of the breaker, and the tab comprises anindicator that rotates with the pivot portion about the axis of rotationof the pivot portion to indicate whether the breaker is in the firstposition or the second position.
 5. The battery disconnect device ofclaim 1, wherein the groove has first and second walls that are spacedapart from each other, and an edge of a first wall and a cylindricalwall of the pivot portion define a first axial groove, and an edge ofthe second wall and the cylindrical wall define a second axial groove,wherein the first axial groove and the second axial groove arecircumferentially spaced apart from each other.
 6. The batterydisconnect device of claim 1, wherein the groove has a floor, and oneedge of the bus bar is disposed adjacent the groove floor.
 7. Thebattery disconnect device of claim 1, wherein the pivot portion furtherhas a second axial face, and the housing defines a first recess on afirst wall and a second recess on a second wall, the first wall and thesecond wall being spaced apart from each other, and wherein at least aportion of the first axial face is engaged in the first recess and atleast a portion of the second axial face is engaged in the secondrecess.
 8. The battery disconnect device of claim 7, wherein at leastone of the first recess or the second recess is an opening in therespective first or second wall of the housing, and the respective firstor second axial face is visible through the opening from outside thehousing.
 9. The battery disconnect device of claim 8, wherein thevisible first or second axial face comprises the indicator thereon, theindicator indicating whether the breaker is in the first position or thesecond position.
 10. The battery disconnect device of claim 1, whereinthe housing comprises a wall that defines an opening, and at least aportion of the bus bar and/or breaker is visible through the opening.11. The battery disconnect device of claim 1, wherein the pivot portionis cylindrically shaped, and the actuation portion extends from aportion of a cylindrical wall of the cylindrically shaped pivot portion.12. The battery disconnect device of claim 11, wherein the actuationportion is wedge shaped and tapers in a radially outward direction fromthe cylindrical wall.
 13. The battery disconnect device of claim 1,wherein the bus bar comprises a first lead and a second lead, the firstand second leads extend outwardly relative to an external surface of thehousing.
 14. A battery disconnect device comprising: a breaker having anindicator on a portion thereof; a housing defining a chamber, thebreaker being disposed in the chamber; and a bus bar disposed throughthe housing, wherein combustion gas from a gas generator causes thebreaker to move from a first position to a second position, whereinmovement from the first position to the second position causes thebreaker to break the bus bar into at least two separate pieces, and theindicator is visible from an external surface of the housing when thebreaker is in the second position, wherein the breaker has a pivotportion and an actuation portion, the actuation portion having anactuation face, the pivot portion having an axis of rotation about whichthe breaker is pivotable, wherein the chamber is in fluid communicationwith a gas generator via an inlet defined by an inlet wall of thehousing, the bus bar extending through the housing and the chamber,wherein the actuation face is adjacent the inlet and inlet wall in thefirst position, and combustion gas from the gas generator pushes on theactuation face to cause the breaker to pivot about the axis of rotationof the pivot portion to a second position, wherein in the secondposition, the actuation face is spaced apart from the inlet and inletwall, wherein: the actuation face lies in a first plane and a secondface lies in a second plane, the inlet wall of the chamber lies in athird plane, the housing further comprises a stop wall that lies in afourth plane and an arcuate shaped wall disposed between the stop walland the inlet wall, the third and fourth planes intersecting oppositethe arcuate shaped wall of the housing, the breaker comprises an arcuateshaped face extending between the actuation face and the second face,the arcuate shaped face being opposite and spaced apart from the pivotportion, the arcuate shaped wall of the chamber faces the arcuate shapedface of the breaker, and the pivot portion of the breaker is disposedadjacent the intersection of the third and fourth planes, wherein thearcuate shaped face of the breaker comprises at least one tooth thatextends away from the arcuate shaped face, the tooth engaging thearcuate shaped wall after the breaker rotates from the first position tothe second position to prevent rotation from the second position to thefirst position, and wherein the at least one tooth comprises a firstplurality of teeth and the arcuate shaped wall defines a secondplurality of teeth that extend away from the arcuate shaped wall andengage the first plurality of teeth after the breaker rotates from thefirst position to the second position to prevent rotation from thesecond position to the first position.
 15. The battery disconnect deviceof claim 14, wherein an angle of intersection of the first and secondplanes is less than 90°.